ROASTED & NON ROASTED CORN FLAKES

MANUFACTURING UNIT
[EIRI/EDPR/4055] J.C. 2189XL

INTRODUCTION

Maize (Zea mays L) is also known as corn, is the world’s third most important cereal
crop after wheat and rice. It has very high yield potential and is commonly known as
“Queen of cereals”. Maize contains about 10% proteins, 4% oil, 70% carbohydrates,
2.3% crude fiber, 10.4% albuminoides and 1.4% ash. Maize has significant quantities of
vitamin A, nicotinic acid, riboflavin and vitamin E. Corn flakes is a popular breakfast
cereal originally manufactured through the treatment of corn.

Corn flakes, or cornflakes, are a popular breakfast cereal made by toasting flakes of
corn. The cereal was first created by John Harvey Kellogg in 1894 as a food that he
thought would be healthy for the patients of the Battle Creek Sanitarium in Michigan
where he was superintendent. The breakfast cereal proved popular among the patients
and the Kellogg Company (Kellogg's) was set up to produce corn flakes for the wider
public. A patent for the process was granted in 1896.With corn flakes becoming popular
in the wider community, a previous patient at the sanitarium, C. W. Post, started to
make rival products. Kellogg continued to experiment and various ingredients were
added and different grains were used. In 1928, he started to manufacture Rice Krispies,
another successful breakfast cereal. There are many generic brands of corn flakes
produced by various manufacturers. As well as being used as a breakfast cereal, the
crushed flakes can be a substitute for bread crumbs in recipes and can be incorporated
into many cooked dishes.

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Crushed corn flakes used for making breakfast items or desserts. Take corn flakes and
crush coarsely with your hands. Raw corn flakes these are the cornflakes which are
unprocessed and raw and are normally used to make snacks like chivda. Before using
them, it's necessary to deep fry them and cook them so as to make them edible. Raw
cornflakes are made from sweetcorn, which is ripened by more than 140 days under sun
before being milled. Milling process removes the corn kernels from the cobs and turns
them into flaking sized grits. These raw cornflakes are then packed and are used as
required.

Cornflakes are a packaged cereal eaten with cold or hot milk. The main ingredient of
cornflakes is corn. Sugar, malt flavoring, and high fructose corn syrup are some of the
other ingredients. Most of them have a high content of glycemic index (GI). Foods high in
GI increase level of sugar in bloodstream very quickly. When insulin is released into the
brain, it naturally decreases the sugar level. This results in a feeling of inactiveness. The
brain has a false sense of starvation and continues to eat. Therefore, cornflakes are not
always healthy as supposed to be.

Cornflakes has quite a high amount of sugar content that exists in the form of high
fructose corn syrup. This is a kind of sugar which is simple carbohydrate, belonging to a
class of chemically-related sweet-flavored essences. Many people add sugar or honey to
their cornflakes and that raises the sugar content and therefore the chances of weight
gain.

Besides the good taste, crispy nature, corn flakesare also popular because of their
friable texture, blend flavour and above all the ease with which itcan be prepared for
consumption. Corn Flakes can be manufactured either of the two white or yellow corns.
The only difference is that flake formed using yellow corn is more dark in colour.

From raw corn flakes (before roasting) corn syrupcan be prepared. It is prepared by
removing starchfrom maize by soaking and treating withchemicals. It is also being used
by liquor industry for manufacture of beer etc.

Few Indian Major Players are as under- Bagrrys India Ltd., K C L Ltd., Kellogg India Pvt.
Ltd., Mohan Meakin Ltd., Mysore Sales International Ltd., Riddhi Siddhi GlucoBiols Ltd.

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 PROJECT LOCATION

Hyderabad is the capital of Telangana in Southern India, located on the banks of the
Musi River and on the Deccan Plateau. Hyderabad and Secunderabad are "twin cities"
near Hussain Sagar Lake (also known as Tank Bund in local parlance) but both cities
have grown so much that now they have become one big metropolis. The city and
district of Hyderabad are coterminous. Hyderabad district is entirely contained within
the Ranga Reddy district of Telangana. Many of the suburbs of Hyderabad were recently
merged into the city, now called Greater Hyderabad.

City Map

A city rich with history and tradition, Hyderabad now competes with Bangalore and
Chennai for the crown of India's IT capital; Microsoft, Amazon and Google have their
India headquarters here.

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Climate

Like many Indian cities Hyderabad has a tropical climate. The best time to visit the city
is from mid-November to mid-February.Temperatures are mild with abundant sunshine
during this time and average temperature range from a low of 15°C (59°F) to a high of
29°C (85°F). March to June is hot and dry with occasional thunderstorms. Highs can
reach 45°C (113°F) or more and lack of air-conditioning can make it feel very
uncomfortable. July, August, September and October can be quite warm and humid and
low pressure systems from the Bay of Bengal during the monsoon season can cause
heavy rain for days.

Transportation

Hyderabad is well connected to all parts of the country by air, rail and road.

By plane

Hyderabad's new Rajiv Gandhi International Airport (IATA: HYD) is located 22 km (14
mi) from the city. Note that the old airport at Begumpet is now closed, except for use by
VIPs. The sleek and well-organized airport is one of the best aviation facilities in India.
The elevated expressway to the airport is now open and takes 20 minutes. Direct
international connectivity from Hyderabad is available for many countries. International
carriers operating from Hyderabad are Air India, British Airways, Emirates, Malaysia
Airlines, Air Asia, Oman Air, Qatar Airways, Saudi Arabian Airlines, Silk Air, Etihad
Airways, Cathay Pacific and Thai Airways.

Domestic connectivity is excellent with Indian airlines operating from here including Air
India, Air India Express, Indian Airlines, Indigo Airlines, Trujet and SpiceJet.

By train

Indian Railways has service to Hyderabad from all over India.

There are three major railway stations serving the twin cities: Secunderabad, Hyderabad
and Kachiguda and a minor station at Begumpet. Most of the trains bound for South
India and North India originate from Hyderabad,and leave via Secunderabad. Hyderabad
Deccan Station is popularly known as Nampally Station. Find all trains to Hyderabad.

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By car

Hyderabad is well connected to other major Metros by road. Bangalore is connected by

NH7 and is at a distance of 560 km. The city is 752 km from Chennai (using highways
NH9 and NH5) and 800 km from Mumbai (NH9 till Pune and the expressway to
Mumbai.) The BangaloNorth-South section is part of the North South corridor which is
being upgraded to a four-lane divided highway. Hyderabad is also known as Hub of
Business.

Vijayawada To Hyderabad to interstate connected between 270 km 4line roadway by

NH65. The RTO Check post of Telangana After Crossing The Kodada Town Will Found
State Border

By bus

Hyderabad is well-connected to all parts of the Telangana and most parts of South and
Western India. Both state government and private buses operate large number of luxury
and ordinary services across the state and neighboring states.

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 CONTENTS

INTRODUCTION
PROJECT LOCATION
CITY MAP
CLIMATE
TRANSPORTATION
BY PLANE
BY TRAIN
BY CAR
BY BUS
PHYSICAL PROPERTIES OF MAIZE GRAINS
AVAILIBILITY OF RAW MATERIAL
RAW MATERIAL
NUTRITION OF CORN FLASK
USES AND APPLICATION
PRODUCT & ITS APPLICATION:
WAYS TO USE CORNFLAKES
1. CORNFLAKES UPMA
2. CORNFLAKES LADOO
3. PEAR ICE AND CRUNCH
4. BUTTER CRUNCH BISCUITS
5. NUTTY CORNFLAKE WHITE CHOCOLATE CLUSTER
6. FRIED ICE CREAM
7. CORNFLAKE CRUSTED FRIED CHICKEN
MARKET SURVEY
MAJOR COMPANIES
SITUATIONAL ANALYSIS USING SWOT:
STRENGTH:
WEAKNESS:
OPPORTUNITY:
THREATS:
TACTICS EMPLOYED IN ORDER TO ACHIEVE STRATEGIC OBJECTIVES:
PRODUCT:
PRICE:
PLACE:
PROMOTION:
PROCESS:
PRODUCT INSIGHTS
DISTRIBUTION CHANNEL INSIGHTS

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REGIONAL INSIGHTS
MANUFACTURING PROCESS
THE PROCESS OF CORN FLAKES IS -
B.I.S SPECIFICATION
TOP 10 BEST CORN FLAKES BRANDS TO BUY IN INDIA
KELLOGG’S CORN FLAKES
MANNA CORN FLAKES PLUS
GO HEALTHY CORN FLAKES
SAVOUR CORN FLAKES
24 MANTRA ORGANIC CORN FLAKES
KWALITY CORN FLAKES
LAWRENCE MILLS CORN FLAKES
BAGRRY’S CORN FLAKES
PATANJALI CORN FLAKES
OHO CORN FLAKES
MARKET POTENTIAL AND MARKETING ISSUES, IF ANY
LEGAL LICENSE FOR FOOD BUSINESS IN INDIA
1. FOOD LICENSE
GST (GOODS AND SERVICE TAX)
PROFESSIONAL TAX
BASIC FSSAI REGISTRATION
MACHINERY SUPPLIERS
RAW MATERIAL SUPPLIERS
MANPOWER
GENERAL
BASISOFESTIMATION
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
6. TRANSPORTATION:
7. WASTE DISPOSAL:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:

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3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TERM LOANS:
8. TOTAL LOAD:
9. LAND AREA/MAN POWER RATIO:
PRODUCT PHOTOGRAPHS
MACHINERY PHOTOGRAPHS
BIG TYPE FLOUR MIXING MACHINE
SCREW ELEVATOR
SV52-II TWINSCREW EXTRUDER INCLUDES ONE SET OF DIES
WATER TOWER
CLOSED TYPE AIR BLOWER WITH DISCHARGING DEVICE
4M VIBRATION COOLING MACHINE
BIG TYPE AIR CONVEYOR 6.5M THREE LAYERS GAS TYPE DRYING MACHINE
CONVEYOR
GAS TYPE HIGH TEMPERATURE VIBRATION HOT AIR ROASTING MACHINE (SIMPLE
VERSION)
SUGAR SPRAYING SYSTEM
SPREADING VIBRATION MACHINE
THREE LAYERS GAS TYPE EXTENDED DRYING MACHINE
5M COOLING CONVEYOR
FLAKER MACHINE
HIGH TEMPERATURE ROASTING MACHINE
RAW MATERIAL PHOTOGRAPHS

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APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

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 COST ESTIMATION

Plant Capacity 2 MT/Day

Land & Building (4000 sq.mt.) Rs. 3.39 Cr
Plant & Machinery Rs. 84 Lac
Working Capital for 1 Month Rs. 93 Lac
Total Capital Investment Rs. 5.45 Cr
Rate of Return 32%
Break Even Point 55%

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